Pump controller system and method
A method and apparatus for a pump control system. One or more embodiments of the invention include a pump controller that can perform a self-calibrating procedure, can provide precise motor speed control, can provide a limp mode before shutting down the motor when system parameters are exceeded and/or fault conditions occur, can detect fault conditions, and can store fault conditions for later retrieval.
1. A method of calibrating a pump having a motor, the pump connected to a water distribution system, the method comprising;
a) providing a constant pressure setpoint;
b) operating the motor in a forward direction;
c) sensing a pressure in the water distribution system;
d) determining whether the sensed pressure has increased by a first pressure increment;
e) increasing an operating frequency of the motor by a first frequency increment if the sensed pressure has not increased by the first pressure increment;
f) storing a speed of the motor as a minimum calibrated speed value when the sensed pressure has increased by the first pressure increment; and
g) setting the minimum calibrated speed value as an initial starting speed of the motor whenever the motor is initially turned on or restarted;
wherein a controller performs at least steps b), c), d), and f) when the pump is installed or a new constant pressure setpoint is provided.
2. The method of claim 1 and further comprising reducing the speed of the motor by a second frequency increment before storing the speed of the motor as the minimum calibrated speed value.
3. The method of claim 1 and further comprising sensing the pressure between the pump and a water tank.
4. The method of claim 1 wherein the first pressure increment is about one pound per square inch and the first frequency increment is about one Hertz.
5. The method of claim 1 and further comprising setting at least one gain based on the minimum calibrated speed value.
6. The method of claim 1 and further comprising sensing the pressure in the water distribution system when the water distribution system is connected to at least one of a well pump system, a municipal water system, a pool system, a spa system, a recreational vehicle water system, a marine craft water system, a turf or irrigation system, and a pressure boost system.
7. The method of claim 1 and further comprising setting a gain for a proportional/integral control loop based on the minimum calibrated speed value.
8. The method of claim 1 and further comprising performing a regulation mode to increase the pressure in a water tank to a tank pressure setpoint.
9. The method of claim 1 wherein the motor is started operating at a minimum operating speed.